Ketonic resin and process of making same



Patented Feb. 5, 1924.

- UNITED STATES TREVOR S. H UXHAM, OF 'BLOOMFIELD,NEW JERSEY, ASSIGNbR, BY MES'NE ASSIGN- TMENTS, TO CARLETON ELLIS, OF MON'ICLAIB, NEW JERSEY.

PATENT. OFFICE.

I KETONIC RESIN AND PROCESS OF MAKING SAME.

K Drawing.

- To all whom it may concern Be it known that I, Txnvon S. 'HUXHAM, a citizen of the United States, residing at Bloomfield, in the county of Essex and State of New Jersey, have invented certain new and useful Improvements in 'Ketonic Resins and Processes of Making Same, of which the following is a specification,

This invention relates to ketone resins and 1 to the process of making same and molded products derived therefrom and relates especially to reactions producing resins from.

The object ofthe invention is to produce various types of resins which are soluble in J available organic solvents and which generally speaking when soluble are fusible and suited for use in the manufacture of shellac substitutes, varnishes, coating compounds, polishes and other purposes to which resins of this general character may be applied in the arts. It is further an object of the invention to produce resins which are substantially infusible, that is do not definitely melt when heated but if raised to a sur'fi-.

ciently thigh temperature char andhburn without liquefying.- Resins of this character have important uses asv binders in the manufacture of plastic articles or molded objects intended for insulating purposes, articles requiring heat resistance, acid and alkali resistance, and to be insoluble in ordi nary organic solvents. i

One feature of the ketnoic resin per se is that it exhibits a remarkable degree of resistance to strong alkalies such as caustic alkali. Practically all of the natural resins are very quickly affected by caustic soda or caustic potash and the same is true of many .of: the synthetic resinssuch as the well;- known phenol formaldehyde condensation products. These synthetlc resins are affected by alkalies even in the cold and submergence in a solution of caustic alkali will able condensing agent preferably a basic Application filed September '10, 1921. Serial no. 499,783.-

completely destroy them in the course of a week or'ten days. On the other hand the ketonic resins will resist caustic alkali in definitely and even on boiling the resin in strong caustic soda little orno destructive.

action takes place. The foregoing does not apply merely. to the infusible ketonic resin but also to the soluble and fusible species and this is particularly the' case with resins made from acetone or methylacetone.

The reaction may be carried out by mixing the reacting materials together in the requisiteproportions and agitating the solution, allowing the mixture to'spontaneously heat to the reaction point which is preferably somewhat above room temperature but preferably not exceeding, at least in the first stages-the boiling point of the ketone.

-The reaction is a vigorous one and if al-' lowed to rogress spontaneously to full extent would explosions. By surrounding the reaction vessel with a jacket of water or otherwise cooling and preferably by vigorous agitation the temperature of the reaction mixture may be controlled within suitable bounds so that resinification progresses gradually and properly and a uniform product of a desirable 1 light color may be obtained. Toward the tial degree of resinification has occurred and the temperature may thereafter be allowed 'to rise to about C. producing a soluble and fusible resinof a light reddish brown or orange color.

One of the most active condensing agents or activators of the reaction is caustic soda or caustic potash. Ammonium hydroxide is not very suitable for the purpose at least under ordinary pressure because it is too dissipate much of the acetone be-, sides causing objectionable foaming or even in}; at 5658 C. a temperature may be main- ,tained at about 50 or less until a substanvolatile and does not have the same condensing action asthe fixed alkalies. Sodium.

or potassium carbonate or bicarbonate, are not especially suited for initiating the reacbelow the boiling point of water.

-tion but may be used to advantage in final resinification steps. As caustic soda or caustic potash is sometimes objectionable owing to a stro alkaline reaction sodium sulphite may used in some cases.

As an illustration of one method of form ing a soluble fusible ketone resin the following may be cited: 200 grams of methyl acetone were treated with 400' grams of 37% formaldehyde solution (formalin) 1n the presence ot cc. of 20% alcoholic caustic soda. The mixture was agitated and cooled to prevent the reaction becoming too violent. As the reaction progressed the solution which was light in color became a light brown and increased somewhat in viscosity. Finally resinification progressed to such a stage that the resin which formed separated rendering the mixture turbid. At this point the reaction was'stopped byaddition of dilute sulphuric acid until the mixture showed a slightly acid reaction. The whole mixture was diluted with several volumes of water and the resin Washed with hot water. It was then readily soluble in acetone and was fusible, melting sligl itllky e resin was then heated to 105 C; for about fifteen hours and was then still slightly fusible but was insoluble in all ordinary solvents such as acetone, alcohol, toluol and mixtures of these solvents also insoluble in,

monochlorbenzol monochlornaphthalene seems to soften the resin considerably and the resin apparentlydissolves some of this solvent because it remained soft at room temperatures. However the resin itself is not soluble in monochlornaphthalene prepared under the conditions set forth..

In referrin to resins as soluble it should be understoo that the degree of solubility in certain organic solvents constitutes the meaning in which the term is used. For

example a resin which I term soluble ace tone resin may be soluble in acetone or alcohol or in mixtures of these solvents but not necessarily soluble in benzol or toluol. The solubility depends upon the degree of resinificationand varies greatly according to the extent of reaction. The initial resin is quite easily soluble in a number of solvents but as resinification progresses solubility in hydrocarbons and alcohol is lost and ketones such as acetone or methyl acetone constitute one of the best solvents for such stage On further resinification solubility in ketones is lost. Hence by watching the reaction carefully and for example withdrawing samples from time to time, cooling or heating as the casemay be to restrain. or increase the reaction, the general degree of resinification may be determined at any given period and the reaction arrested at that point if desired either by adding a large volume of water, by cooling, or by adding an acid such as sulphuric, hydrochloric, acetic, bone or other acid.

In another case to 200 grams of methyl sided. Further cooling arrested the reaction and the cooling water was withdraw thereby allowing the reaction mixture to heat up again, the temperature finally aroseto about C. At this point turbidity again was observed, a heavy reddish liquid settling to the bottom. This was com-- posed of. the initial resin together with some acetone. A this point two procedures are possible, (1) allow{ the reaction mixture to cool and the resin: to separate completely from the aqueous layer above, draw oil the aqueous layer or the resin solution thereby effecting a separation or (2) pour the reaction mixture into a considerable volume of water or add Water to the former thereby precipitating the resin in a soft plastic state in which form it may be kneaded in hot water to wash out alkali. In the present invention I preferably allow settlingto take place and draw oil the aqueousalkaline layer which ma be used if desired. in further reaction. he heavy At this point the viscous resin solution is very soluble if not freed -from the acetone associated with it and may be very readily diluted at-this stage with further quantities of acetone or other suitable solvent including benzol and other hydrocarbons and a small amount of a suitable ,acid such as acetic or hydrgchloric acid added to precisely neutralize the alkali. The resin in this form is then ready for use as a coating composition and s the like or for impregnating suitable fillers to produce'compositions intended for molding purposes. The solution also may be used for impregnating paper, cloth or'other materials which maybe used for various purposes including the formation of dense sheets of insulating materials etc. by hot pressing a plurality of impregnated sheets. While I prefer to employ aqueous formaldehyde it is also possible to carry out the reaction. with paraform and other anhydrous formaldehyde compounds containing reactive aldehydes. In some cases I also may employ acetaldehyde 'or'the para compound; Furfural also may be added .in some cases. i 5

As it is frequently an object in making a ton' other alkaline solutions.

'5 than is required to-accomplish resinification when producing resins orresin-so'lutions intended for'use as shellac 's bstitutes.

It may be noted that coating solutions suctg as I have described made with the keresin are very different from shellac heir resistance-to alkali. A-sur'iace'var- ;nished with shellac is immediately turned purpleand destroyed by contact with so-- dium carbonate-ammonia or caustic-alkali Whereas a surface coated with the 'keton'ic resin is as indicated, remarkably resistant.

This is of advantage when varnishes are used for fioors'or places where subjected to the action of strongly alkaline soaps m- The resin also may be used for 'coating'orflinin'g Wooden or other tanks which would be aflected by alkaline solution,' also-a's a coating for con- 'crete and cement-surfaces. '10 cic. of saturatedalcoholiccaustic soda was added tdlOO 'gI-MHS of acetone and then 7 40 grams of paiaform wererin'troduced. 'The reactioncom'menoed almost immediately and ether wasadded'tocool tiny-mix- "ture. The reaction was allowed to proceed slowly until "the solution was yery viscous and was thenplacedain an'oven at 100 C. and maintained -'at this temperature 'over night; A hard resin which'was'somewhat opaque was obtained. It was then 'found to be 'in'fusible showing that even at 100 C. in t the presence of the caustic soda t'he'vre- 1 action progressedto dorm an intusible product. =In another cas'e 100 grains o'f acetone, 10 c-.c.of-saturated alcoholic caustic soda and :100 grams of -/paraform were allowed to react togetheryto produce -a-thin "varnish.

---above resin I find lt desirable to add a lu-- At this :point a smallamount' of-an'alco- --holic solution loftboric acid was introduced -to'--'neutral'ize the alkali. The solution eloudedf slightly and ,the reaction stopped completely. :Amnionia aga's 'wasdnt'roduoed and was found to clear the solution but fivhen further heated the reaction of' resinification did ;ndt' continue. Moreeparaform (and alcoholic caustic soda was necessary to -com1ilete the reaction to --an intusible resinh A solut'ion of this 'lresin in 'rflZZGtQIlByiLfiOIdBd. a iliquidmfm light yellow color which could heusedasa yarnish. y 1

Soluble resins made according to the foregoin process may be used to impregna-teia' fi ler' such as wood flour or may be -'admi-Xed with other suitable fillerssuch as a'sbestos, china clay, whiting, pigments of various sorts and mineral matter of various descriptions to Iform a plastic mass eabeing molded into any "desiredi 'nder-'- h eat andpressure. The-mold ed articles obtained without further transformation of the resin :are of 5 course softened by heat (and formany purposes articles-are required which are resistant to heat.

For this purpose therefore it is necessary to cause 'fthe resin to -reactqh rther to obtain r the infusible product. This maybecarried out in various ways and I shall not attempt to give. all the differentmethodswhich may be utilized for/eflecting such transformation. v

The filler may be treated with an alcoholic or acetone solution of the soluble 'resin xlr'red and the material obtained ground to a powder "then treatedwith a slution containing formaldehyde or parafOrm and caustic soda, sodium sulphi-te or sodium carbonate. The material is again carefully dried and ground when it is ready to be molded under heatand-pressure to form a hard-dense substantially infu'sible article.

0r the-solution of the soluble resin may be treated with formaldehyde and alkali or with alkali alone and --iadmix' ed' with the fillerf This composition isdried and, may then be .molded. In other cases a resin which is fusible but inot readily soluble may he :ground in =a ball -mill with the filler to secure a thorough 'commingling. Still another method which is advantageous on account-of low-cost of handling 'is mixing'on heated rolls. In these-methods the resin is thrown on the heated rolls-and melted, the

resin adhering to 'the {rolls and "mixing.

which the whole mass is stripped off by means of steel blades and is usually run through 'water;-cooled .rollswto produce a standard size sheet and :at the same time prevent the reaction from being completed before molding.

-In aking- :goo'd molded articles from the bricati'ng agent. Stearictncid or waxy manarily 2-4% being suflicient. For flaking A pur oses where the resin does not fl'ow rea ily-in the mold, --high boilingpolntsolvents ma be used. v

I have ound-that-this+resin does not have any undesirable action on' thesteel molds *commonly employediin preparing plastic articjles. This is of importanee as the mo lds are 'very expensive and injury theretoby the-resin would=constitute a serious drawback to its use. 1

Wood flour is the most'useful filling ma-- terial for the great majority of plastic ar ticles owing to the relative lightness of the finished article in comparison with products made from heavy mineral fillers. The

wood flourpreferably used should be of low' resin content containing not more than 7% water-and must not on any account contain metallic or abrasive material. Wood flour ing of phenol formaldehyde condensation products under a pressure ranging from two to three thousand pounds per square inch or higher. A temperature of from 100 C. to 200 C. may be used, the time 9f cure de creasing as the temperature is increased. Cooling is advisable but not absolutely necessary. Some of the ketonic resins obtained by the present process are as noted above hi hly sensitive to heat changing with remarka le' speed to infusible products. This is of very great advantage in molding operations as it enables the time of curing to be reduced over that required for many other mOlding. preparations. For example in curing hard rubber an hour or more may be employed in the vulcanizing operation. In molding certain phenol formaldehyde condensation compositions from five minutes to half an hour "may be needed depending upon the sizeof the inolded' piece and largely on the temperature employed. With the present form of resin (at least with the more sensitive types) articles may be cured to a sufficient degree in one or two minutes in many instances. y

As the commonly employed filler namely, wood flour is relatively cheap while the resinous material is substantially more costly it is desirable to use ;a minimum amount of resinous binder in molding compositions It is necessary to have enough "to cover, the particles of'fi ler and form a smooth surface of goo'dfinish for most pur:

poses. A mixture of equala.p'arts. of resin and wood flour gives aproduct the surfaceof whichis Y thoroughly resinous- "without any rou 'henedappearance-or mottled efiect due to bres showing -through.' With many resilio'uscompositibn the flowabili-ty and site ' 'fiel d. {My inventioutherefore .also com-.

otherqualities are such that or more of resinous material may required there-:

by adding considerably'tothe expense of manufacture. With the present resin-I may secure molded articles "-o f-ffsatisfactory quality in many instances;- l!:y='using much less resin, as for example 0" y QO or';30%, and thus greatly :reduce the, costof the molded article; This ability; to usemiiit mum amounts of resin, together with the fsensiti'veness of the resin to curing thus reducin labor costs, makes my invention or 'consr erable importance in the molding prisestheiise of ketonic resins in minimum amountsito' produces art cles of good' su'rface finish especially einbracing -compositions containingordmarily not below- 20% binder present ifng a ent. i v

e process of making an insoluble and "infusible' resin which comprises reacting onthe sulphur resins, may be incorporated with" the resin made according to'my process to form various compositions of diversified characteristics. Some of these may be used as varnishes, paints or other coating compositions, or may be used in the manufacture of molding powders. I do not lay claim to the sulphur chloride phenol types of resins thesebeing the basis of certain applications for patent by Carleton Ellis.

The foregoing resins may be prepared in so far as possible simultaneously with the production of the ketone resin or may be separately prepared and dissolved in the acetoneor other ketone employed and the latter subjected to resinification. In carrying out the process in this way the initial solution.

may be somewhat viscous due to ,dissolved resin and especial care should be taken to avoid'too vigorous reaction and loss of material by foaming over. The reaction in this or steam and the reaction may be carried out either'by mixing all the ingredients together in complete amount required or the method may be varied by adding the formaldehyde or aldehyde reagent gradually to the acetone or other ketone or vice versa. In a similar manner the activating agent may be incorporated with either of the resinifying substances."

' While I have gone into considerabledetail indisclosing the'processes illustrative of my invention it should be understood that I do not limit myself to any of the precise details set forth, various modifications being possible which fall within the scope of my mvention or the equivalency of the claims here inafter appended. I

What I claim is 1. The process of with formaldehyde and an alkaline making an insoluble and infusible resin which comprises reacting on a soluble and fusible ketone-aldehyde resinv activate I 'asoluble and fusible ketone-aldehyde resin with f0 maldehyde and caustic alkali.

3. The process of making an insoluble and infusible resin which comprises reacting on a soluble and fusible ketone-aldehyde resin with an aldehyde and an alkaline activating agent. 4. The process of making an insoluble and infusible resin which comprises reacting on a 10 soluble and fusible ketone-aldehyde resin vviltlh aqueous formaldehyde and caustic alka 5. In the process of making ketone-aldehyde resin the steps which comprise agitating an aqueous solution of an aldehyde and (a 'ket-one in-the presence of an activating agent whereby a resin 1s formed and reactmg upon such resin with formaldehyde in the presence of an alkaline activating agent. TREVOR S. 

